CASE STUDY | In-service Automated UT Corrosion Mapping of Pipeline at Risk of Sulfidation

IRISNDT sought a solution for automated corrosion mapping of a high-temperature pipeline prone to sulfidation. Using ultrasonic testing (UT), they measured remaining wall thickness in refinery piping circuits, ensuring reliable scans with durable transducers to maximize productivity.

CASE STUDY | In-service High Temperature UT Inspection Survey by MISTRAS at a U.S. Oil Refinery

Mistras, a leader in inspection services, faced a challenge at a US West Coast refinery. They needed to perform Ultrasonic Testing (UT) on pipework and equipment operating at high temperatures (350 °F to 700 °F) using specialised transducers. The goal was to measure thickness at corrosion monitoring locations with minimal downtime, ensuring system integrity.

CASE STUDY | In-process weld repair of ammonia converter with HotSense™ TOFD

High-temperature TOFD inspection was conducted during weld repairs at elevated temperatures and varying fill levels, providing accurate, repeatable defect detection. This approach eliminated the need for cooling and reheating, reducing maintenance time and increasing productivity by performing both welding and inspection simultaneously.

CASE STUDY | Steam corrosion in CCGT power plant

Advanced asset integrity solutions, including HotSense probes and wireless CALIPERAY nodes, ensure safe operation of high-pressure steam lines in a power plant. These technologies offer precise, real-time monitoring at temperatures up to 600 °C, reducing inspection costs, enhancing safety, and minimizing operational disruptions. The system also detects wall loss and issues like leaking valves, providing confidence in asset performance without the need for frequent shutdowns.

CASE STUDY | High-temperature TOFD for high-pressure steam lines

Wright Quality Services (WQS), a leading Canadian NDT service provider, conducted routine maintenance inspections on a high-pressure steam line for a refinery operator. Utilizing advanced Phased Array Ultrasonic Testing (PAUT) and high-temperature Time of Flight Diffraction (TOFD) methods, WQS effectively detected weld root erosion under extreme conditions exceeding 300 °C. The inspection, focused on identifying early signs of deterioration, provided high-resolution imaging and superior accuracy, ensuring the reliability of critical welds in high-pressure steam systems.

CASE STUDY | Energy from Waste Wall Loss Monitoring

An Energy-from-Waste plant improves operational reliability by installing a monitoring solution for high-precision wall-thickness measurements, minimising shutdown risks.

BLOG | Experience Precision at your Fingertips

In industries requiring accurate thickness gauging and corrosion detection, ensuring the safety and longevity of critical assets is paramount. HotSense™ HS782i by Ionix is engineered specifically for extreme environments, providing precise measurements of wall thickness from 1 to 25 mm at temperatures up to 200 °C. Its compact, fingertip-sized design allows for easy access to hard-to-reach areas, making on-stream inspections faster and more efficient. With cutting-edge technology and durable construction, HS782i stands out as the go-to solution for on-stream inspections aiming to maintain equipment integrity under challenging conditions.

PRESS RELEASE | “Fusion-H₂”

Ionix awarded UK government funding to develop ultrasonic meter designed to measure hydrogen flow.

CASE STUDY | Wear Monitoring of Iron Ore Crusher Hoppers

Ionix HotSense was used to provide frequent, high-quality wall thickness trends, ensuring the customer knows the hopper’s condition and remaining life. Wall loss trends help predict and schedule maintenance, reducing outages and maximizing production. Changes in wall loss rates can adjust maintenance frequency as needed. The system is installed outside the hopper, increasing safety by reducing personnel exposure to hazards like working from heights and rope access.

CASE STUDY | Automated corrosion monitoring of alkylation units

Non-invasive, corrosion trending with wireless ultrasonic probes and monitoring system to maximise throughput and run length of variable feedstocks.

CASE STUDY | On-Stream Corrosion Inspection Survey using a High Temperature UT Probe

A solution was sought by a leading inspection services term contractor for one of their clients operating a large petrochemical refinery to conduct in-service corrosion surveys across their facilities infrastructure. UT is critical to the plant’s needs and is used extensively for corrosion surveys, but the refinery includes assets with surface temperatures from 120°C to over 350 °C including gas boilers, pressure vessels and piping.

Read our latest case study that highlights why on-stream inspection requires transducers with efficient acoustic coupling, and which can reliably make high-temperature wall thickness measurements to prevent the need for unplanned shutdown and maintain productivity while reducing costs.

CASE STUDY | In-Service Gas Void Detection and Monitoring in Nuclear Energy

The ability to detect gas voids in cooling water lines was required by one of the largest electric power holding companies in the US, generating electricity from mixed sources, including 6 nuclear plants. Find out ho the Ionix solution helped.

APPLICATION INSIGHT | Optimising the Management and Maintenance of Mining Equipment

HotSense™ is a non-invasive ultrasonic wear monitoring solution born out of the extreme environments of the energy sector:​ 

For users of critical components or linings susceptible to wear​;

Who want to  always know the remaining life of their assets;

So that they can shorten outages to maximise availability and reduce outage costs​.

Unlike manual inspection and invasive technologies, HotSense™ provides direct wall thickness trending loss and detection of changes to predict maintenance intervals whilst plant is running.

Field Data Logging Kit (FDLK)

HotSense™ Field Data Logging
Kit (FDLK) for automated
ultrasonic measurement
logging. For the rapid deployment and management of WirelessHART ultrasonic projects and data
collection.

APPLICATION INSIGHT | Optimising the Management and Maintenance of Buried Tailing Lines

Ionix EchoCorr™ is a non-invasive ultrasonic thickness monitoring system suitable for the mining, chemical and oil and gas industries to optimise the management and maintenance of buried tailing lines. Explore this Application Note for more information.

CASE STUDY | Erosion Monitoring of Buried Tailings Lines

A solution was sought to monitor erosion caused by ore tailings from a mining operation in South America. The subsequent wall-loss has the potential to cause failures and loss of containment, resulting in lost productivity, and damage to nearby population and environment.

CASE STUDY | Ultrasonic monitoring of molten salt for energy

A solution was sought by a renewable energy plant operator to monitor the thermophysical properties of molten sodium- potassium nitrate “solar salt” at temperatures exceeding 360 °C / 680 °F.

BLOG | You Are What You Refine!

Having solutions that can produce wall thickness readings that are far more frequently than what traditional manual inspection can offer puts decision making capability on par with process change as demand is placed on the asset and leads to improved profitability and enhanced safety. Find out more in our latest blog.

Application Note – High-Temperature Weld Root Corrosion Inspection

Ionix high-temperature TOFD transducers, with integrated wedges, are suitable for weld inspections at continuous elevated temperatures up to 350 °C. Here, the transducers with integrated wedges are mounted on to a modified EddyFi Lyncs scanner for high-temperature encoding, with high-temperature couplant, connected to
commercially available Mantis UT set, and a carbon steel pipe weld inspected at 200 °C for weld root corrosion.

BLOG | Introducing the HotSense™ Field Data Logging Kit (FDLK)

Introducing the Field Data logging Kit (FDLK), for the rapid deployment and management of WirelessHART ultrasonic projects and data collection. Ready to deploy data collection, node control and remote access solution for HotSense™ WirelessHART sensors.